Mounting Arrangement for Turbulators of a Furnace Heat Exchanger

ABSTRACT

A boiler apparatus having a combustion chamber, a container for receiving liquid to be heated, a flue, and tubes passing through the container to join the combustion chamber and flue includes a tube cleaning system comprising outer edges of turbulators that are in contact with the respective inner tube surface, a horizontally extending shaft over the tubes, and pivotal connections by which the downwardly depending turbulators are connected to the shaft. The shaft defines an axis about which it is pivotal, where by pivoting of the shaft the turbulators are moved relative to the tubes in vertical longitudinal sliding movement from an operating position to a raised position and back thereto so as to generate a cleaning action against the inner tube surface. Each turbulator is removably attached to the shaft independently of the other allowing each to be removed for cleaning without disassembling a remainder of the tube cleaning system.

FIELD OF THE INVENTION

The present invention relates to heat exchangers, and more particularly to an arrangement for mounting turbulators of a heat exchanger.

BACKGROUND

Boilers commonly consist of a boiler housing, a combustion chamber, a water jacket for receiving the liquid to be heated, a flue for discharge of the combustion products and a series of tubes arranged to pass through the water jacket, thereby connecting the combustion chamber and the flue. Thus, heated gases produced in the combustion chamber flow up the tubes to the flue. While the heated gases pass along the tubes, heat from the gases is transferred to the liquid in the water jacket. Furthermore, the efficiency of heat transfer may be increased by creating turbulence in the flow of the heated gases by, for example, placing flights or spirals within the tubes which are sometimes referred to in industry as ‘turbulators.’ However, soot and other debris from the heated gases will deposit along the inner surface of the tubes as well as on the flights and spirals. This in turn greatly decreases the efficiency of heat transfer, resulting in higher fuel costs. Eventually, the boiler must be shut down and each of the heat exchanger tubes cleaned individually, a difficult and time-consuming process due to the presence of the flights and/or spirals inserted within the tubes.

Systems have been developed to provide a means for quickly and easily cleaning heat exchanger tubes. These systems typically operate by longitudinal sliding movement of the respective flight in its tube by which contact of the flight with an inner surface of the tube is generated in order to remove deposited material from the inner tube surface. For example, the respective turbulator may generate a scraping action against the inner tube surface or may collide therewith during its longitudinal movement in a manner knocking off the deposited material as the turbulator is displaced vertically.

In spite of the availability of such a cleaning system, the turbulators must still be periodically removed from within the heat exchanger tubes for cleaning of the turbulators as well as to provide unobstructed access for periodic cleaning the inner surface of the respective tube, for example brushing of the tubes on an annual basis. Conventional arrangements that provide the tube cleaning operation described in the previous paragraph commonly require disassembly of the entire tube cleaning system in order to clean any one of the turbulators which typically must be removed from the tubes therefor. This increases time needed for cleaning of the turbulators. For example, the entire assembly may have to be lifted vertically out of the tubes or several turbulators at once removed from the tubes which may be cumbersome. Furthermore, in this type of arrangement several if not all of the turbulators must be simultaneously lowered back into the tubes which requires aligning multiple turbulators with the corresponding tubes.

SUMMARY OF THE INVENTION

According to an aspect of the invention there is provided a boiler apparatus comprising:

a boiler housing;

a combustion chamber in the boiler housing for generating heated gases including combustion products;

a flue connected to the boiler housing for discharge of the combustion products;

a container in the boiler housing for receiving a liquid material to be heated;

a plurality of vertical tubes passing through the container and extending from the combustion chamber to the flue for receiving the heated gases and communicating heat from the heated gases to the liquid material, said tubes each having an inner surface over which the heated gases and combustion products pass and an outer surface in communication with the liquid material;

each tube having therein a helical turbulator arranged to create turbulence in the flow of the heated gases, thereby increasing heat transfer from the heated gases to the inner surface of the tube;

the turbulator comprising a strip with outer edges thereof defining outside turbulator edges and following a helical path about a central axis along the respective tube such that at least one of the outer edges is arranged in its helical path generally at the inner surface of the tube so as to be arranged for contact with the inner surface of the tube;

the tubes being arranged each to one side of the next so as to generally form a row;

the plurality of turbulators being mounted with a pivotal connection to a common shaft extending parallel to the row of the tubes;

the shaft being pivotally movable about its axis so as to effect through the pivotal connection of each turbulator a longitudinal vertical sliding movement of each of the turbulators relative to the respective tube from an operating position to a raised position and back to the operating position, the contact of said at least one of the outside turbulator edges and the movement thereof effecting a cleaning of the inner surface to remove combustion products deposited on the inner surface by the heated gases;

the pivotal connection of the respective turbulator including a bracket forming a channel with an open side receiving the shaft therethrough and an ear supported on the bracket opposite the open side wherefrom the turbulator pivotally depends downwardly;

the bracket being attached to the shaft by a removable pin passing through apertures in the bracket and the shaft so as to hold the bracket of the respective turbulator in fixed relation to the shaft;

whereby each turbulator is removably attached to the common shaft independently of the other turbulators.

For example, in one arrangement the bracket is generally C-shaped so as to generally follow part of a circumferential transverse periphery of the shaft.

Typically the turbulator is arranged depending downwardly from a location radially of the axis of the shaft such that the ear extends outwardly from the shaft in a generally radial direction relative thereto.

The removable pin comprises an elongate pin portion extending generally diametrically through the shaft through said cooperating apertures and a clip portion following an arcuate curving path about a circumferential periphery of the shaft from one end of the pin portion where the clip portion is pivotally connected to the pin portion to an opposite end of the pin portion where a terminus of the clip portion is matingly securable to the pin portion externally of the shaft.

Typically the pin portion where it passes through the bracket and shaft has a smooth cylindrical surface.

Thus typically the pin is not threadably mated with the bracket nor the shaft at the respective apertures so that a time required for installing or removing a selected one of the turbulators is expedited.

Typically the clip portion of the pin follows the arcuate curving path about a portion of the circumferential periphery of the shaft that is opposite the ear from which the turbulator depends.

Preferably the turbulators are at spaced positions along the shaft each longitudinally of the next.

Preferably the turbulators are disposed in an alternating arrangement relative to the shaft such that the turbulators are staggered relative to one another about the axis of the shaft.

BRIEF DESCRIPTION OF THE DRAWINGS

One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:

FIG. 1 is a front elevational view of boiler apparatus according to the present invention.

FIG. 2 is a cross-sectional view along line 2-2 in FIG. 1.

FIG. 3 is a top plan view of the boiler apparatus of FIG. 1 with a portion cutaway to show a heat exchanger of the boiler apparatus.

FIG. 4 is an enlarged sectional view of a portion of the boiler apparatus, similar to how it is illustrated in FIG. 2, with some components cutaway and some components omitted showing a tube cleaning system of the boiler apparatus.

FIG. 5 is a perspective view of the tube cleaning system.

In the drawings like characters of reference indicate corresponding parts in the different figures.

DETAILED DESCRIPTION

There is illustrated in the accompanying figures a boiler apparatus generally indicated at 10. Generally speaking, the boiler apparatus 10 is a conventional such apparatus in which combustible material is burned, thereby generating heated gases and combustion products which pass through tubes 13 and out a flue 15 wherefrom they are discharged from the apparatus. Heat is extracted from the heated gases and combustion products in a conventional heat exchanger 18 of the boiler apparatus that is formed by the tubes 13 and a conventional container 20 through which the tubes pass. That is, as the heated gases and combustion products pass through the tubes 13 from a furnace 22 of the apparatus 10 to the flue 15, the heat therein is transferred through a wall 24 of the respective tube to a liquid shown schematically at 25 that is contained in the container 20. The container 20 is sometimes referred to in industry as a water jacket. The liquid 25 is then circulated to another location (not shown) externally of the boiler apparatus 10 for applying the heat thereto, for example a space to be heated or a consumable water supply.

More specifically, the boiler apparatus 10 comprises a housing 27 substantially enclosing components of the apparatus 10 as will be better appreciated hereinafter. The housing includes side walls 29A-29D, a top wall 30, and a base 31.

Within the housing 27 there is defined a combustion chamber 34 where combustion of the combustible material, for example wood, occurs so as to generate the heated gases and combustion products which are by-products of the combustion process. The combustion chamber 34 is partitioned into upper and lower chambers 34A and 34B by a horizontal dividing wall 36 spanning from a front of the combustion chamber at the front housing wall 29A to a rear of the combustion chamber defined by an interior wall within the housing 27.

It is in the upper chamber 34A where the combustible material is inserted, typically through an upper one 38 of a plurality of access doors 38, 39 in the front side wall 29A of the boiler housing 27 used primarily for this purpose. A lower one of the access doors 39 sized smaller than the door 38 and which is adjacent the horizontal dividing wall 36 is usable for readily lighting the combustible material at its base.

Thus, initial burn of the combustible material occurs in the upper chamber 34A in order to generate the heated gases and combustion products. These gases and combustion products then flow downwardly from the upper chamber to the lower chamber 34B through, for example, holes in the horizontal dividing wall 36 that form passageways therefor.

In the lower chamber 34B, which forms the furnace 22 of the apparatus, a majority of that which is received from the upper chamber is consumed in a secondary burn so as to extract additional heat therefrom, thereby raising the gases flowing through to the tubes to a highest temperature within the combustion process occurring in the boiler apparatus. The lower chamber 34B is sized larger than the upper chamber in terms of depth between the front side wall 29B and the rear side wall 29B of the housing so as to extend from underneath the upper chamber 34A to beneath the tubes 13, which together with the container 20 are located in the housing 27 rearwardly of the upper chamber 34A.

A plurality of the tubes 13 pass through the container 20 and extend vertically from the lower combustion chamber 34B to the flue 15, which is connected to the housing 27 at the top wall 30. The tubes are thus arranged for receiving the heated gases and communicating heat from the heated gases to the liquid material. As such, each tube has an inner surface 24A over which the heated gases and combustion products pass and an outer surface 24B in communication with the liquid material 25 in the container 20.

Within each tube 13 there is provided a helical turbulator 42 which is arranged to create turbulence in the flow of the heated gases, thereby increasing heat transfer from the heated gases to the inner surface 24A of the tube as known in the art.

Each turbulator 42 of the illustrated arrangement comprises a strip of substantially rigid yet resilient material 44 with outer edges 45A, 45B thereof arranged to follow a helical path longitudinally of the respective tube such that at least one of the outer edges 45 is arranged in its helical path at the inner surface 24A of the tube. That is, the helical path winds about a central axis coaxially along the respective tube and has a radius substantially equal to an inner diameter of the tube. For example, as in the illustrated arrangement the strip of the material is arranged in a helix where both outer edges 45A, 45B following parallel side-by-side paths but where only one of the outer edges 45A is at the inner tube surface 24A. In an alternative arrangement (not shown), the strip of the material may extend across the tube and may be helically twisted such that the outer edges follow paths substantially symmetrical relative to the central axis so as to be opposite one another and where both outer edges of the strip are arranged at the inner tube surface.

It will be appreciated that the outer edges 45A, 45B of the strip 44 define outside turbulator edges of the respective turbulator, and thus, as described in the previous paragraph, the respective outside turbulator edge which is at the inner tube surface 24A is arranged for contact therewith in a sufficiently close fit of the turbulator and respective outside turbulator edge with the inner tube surface such that that outside turbulator edge in longitudinally vertical sliding movement of the turbulator can effect a cleaning action of the inner surface to remove deposits of the combustion products on the inner tube surface which otherwise reduce the efficiency of the heat transfer. In the illustrated arrangement there is provided a minute clearance gap between the inner tube surface 24A and the respective outside turbulator edge 45A thereat such that the turbulator may move transversely of the central tube axis in a vibratory manner as the turbulator is slidingly displaced along the tube. As such, the outside turbulator edge 45A at the inner tube surface 24A collides therewith in a manner knocking off the products deposited by the heated gases. In an alternative arrangement, the outside turbulator edge(s) at the inner tube surface 24A may define a sliding fit with the inner surface of the tube such that the contact of that outside turbulator edge(s) and the movement thereof effects a scraping action of the inner surface of the tube to clean same.

A tube cleaning system 48 of the boiler apparatus is formed by a shaft 50 extending horizontally through the boiler housing 10 above top ends of the tubes 13 with a lever 52 on one end externally to the housing 27 for operation, and pivotal connections respectively indicated at 54 that join the turbulators 42 to the shaft so that they are movable in the longitudinal sliding movement to clean with the outside turbulator edges 45 the inner tube surface as the shaft 50 is pivoted about its axis.

More specifically, in the longitudinal sliding movement the respective turbulator is moved relative to the tube from an operating position to a raised position and back to the operating position, with the contact of the respective outer edge of the strip and the movement thereof relative to the tube effecting a cleaning of the inner surface 24A to remove combustion products deposited on the inner surface by the heated gases.

The tubes 13 are arranged each to one side of the next so as to generally form a row parallel to an axis of the shaft such that the row extends across a width of the housing 27 from one side wall 29C to the opposite side wall 29D.

More specifically, in the illustrated arrangement the tubes arranged side-by-side form a zig-zagging pattern relative to the axis of the shaft which is a central axis through the zig-zagged pattern of the row of tubes. Thus, as best shown in top plan view in FIG. 3, the tubes 13 relative to the shaft are disposed in an alternating arrangement so that the tubes are staggered relative to one another about the shaft 50 which is central therefor. Furthermore, the tubes are spaced longitudinally apart one from the other along the length of the shaft.

The pivotal connection 54 includes a bracket 56 forming a channel which is receivable over a lengthwise (longitudinal) portion of the shaft in a manner covering a portion of a circumferential transverse periphery of the shaft 50.

Thus, in transverse cross-section as best shown in FIG. 4 the bracket is generally C-shaped so as to generally follow part of the circumferential transverse periphery of the shaft.

Furthermore, the bracket therefore has an open side at 59 through which the shaft 50 in fixed position in the housing is passed as the bracket 56 is placed thereover.

Opposite the open side 59 there is provided a plate forming an ear 61 oriented in a radial plane of the shaft normal to the shaft axis and which extends outwardly therefrom in a radial direction. It is from the ear where the turbulator 42 depends downwardly into the respective tube 13. The strip 44 is supported in fixed relation to a hanger 63 pivotally connected at the ear 61 by a pivot pin P defining a pivot axis parallel to and spaced radially from the shaft axis, thereby forming the pivotal connection 54. A top end of the strip 44 is hooked through an aperture at a bottom of the hanger 63 so as to connect the turbulator thereto.

There is provided a removable fastening pin 66 to attach the bracket in fixed relation to the shaft. The fastening pin 66 passes through apertures 68, 69 in each of the bracket 56 and the shaft 50 which are cooperative with the pin and can be properly aligned with one another when the bracket is inserted over the shaft. In the illustrated arrangement, the set of cooperating apertures 68 in the bracket and that aperture 69 in the solid shaft extending diametrically therethrough are aligned linearly along a diameter of the shaft.

The fastening pin 66 comprises an elongate rigid pin portion 71 with a smooth cylindrical surface which is passed diametrically of the shaft 50 through the two sets of apertures 68, 69. Thus, it will be appreciated that in the illustrated arrangement the pin portion is not threadably mated with the shaft or bracket at the respective apertures 68, 69, whereby installation and removal of the pin 66 may thus be expedited. Further to the pin portion, a clip portion 72 of the fastening pin is provided which is pivotally connected at one end 71A of the pin portion. The clip portion is curved so that from its connected end to its terminus 72B the clip portion follows an arcuate curving path. As such, the clip portion is shaped to traverse a portion of the circumferential periphery of the shaft in order for the terminus 72B to matingly close the pin 66 at a distal end of the pin portion. Thus, the clip portion is resiliently flexible so that the terminus may be slid over an end portion of the pin portion 71 that protrudes beyond an outer face of the bracket 56. For example, the pin portion 71 includes a circumferentially extending groove which matingly receives the terminus of the clip portion to matingly close the pin 66 which is an arrangement common to the field of fastening pins. The pin portion 71 where the clip portion 72 is hinged thereat is enlarged radially of that part of the pin portion passing through the shaft 50 so as to provide a circumferentially extending surface for resting against an outer face at a top of the bracket 56.

Thus, each turbulator 42 is attached to the common shaft 50, on which all turbulators are supported, independently of every other turbulator. As such, each turbulator is removable from the shaft and thus from within the respective tube for cleaning without having to disassemble an entirety of the boiler apparatus' tube cleaning system 48.

Removal of the respective turbulator from the tube may be achieved by removing the fastening pin 66, rotating the turbulator still within the tube so as to displace the bracket from its position by which its shape follows the circumference of the shaft, and then lifting the turbulator vertically upwardly out of confinement within the tube. The reverse of these steps may be performed in order to insert the respective turbulator into the corresponding one of the tubes, for example after cleaning of the turbulator.

Additionally, it will be appreciated that an end of the shaft 50 opposite the lever 52 is supported in a receptacle at a wall of the heat exchanger container 20 and a portion of the shaft adjacent the lever is supported in a tubular sleeve so as to carry the shaft in its pivotal movement.

Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. 

1. A boiler apparatus comprising: a boiler housing; a combustion chamber in the boiler housing for generating heated gases including combustion products; a flue connected to the boiler housing for discharge of the combustion products; a container in the boiler housing for receiving a liquid material to be heated; a plurality of vertical tubes passing through the container and extending from the combustion chamber to the flue for receiving the heated gases and communicating heat from the heated gases to the liquid material, said tubes each having an inner surface over which the heated gases and combustion products pass and an outer surface in communication with the liquid material; each tube having therein a helical turbulator arranged to create turbulence in the flow of the heated gases, thereby increasing heat transfer from the heated gases to the inner surface of the tube; the turbulator comprising a strip with outer edges thereof defining outside turbulator edges and following a helical path about a central axis along the respective tube such that at least one of the outer edges is arranged in its helical path generally at the inner surface of the tube so as to be arranged for contact with the inner surface of the tube; the tubes being arranged each to one side of the next so as to generally form a row; the plurality of turbulators being mounted with a pivotal connection to a common shaft extending parallel to the row of the tubes; the shaft being pivotally movable about its axis so as to effect through the pivotal connection of each turbulator a longitudinal vertical sliding movement of each of the turbulators relative to the respective tube from an operating position to a raised position and back to the operating position, the contact of said at least one of the outside turbulator edges and the movement thereof effecting a cleaning of the inner surface to remove combustion products deposited on the inner surface by the heated gases; the pivotal connection of the respective turbulator including a bracket forming a channel with an open side receiving the shaft therethrough and an ear supported on the bracket opposite the open side wherefrom the turbulator pivotally depends downwardly; the bracket being attached to the shaft by a removable pin passing through apertures in the bracket and the shaft so as to hold the bracket of the respective turbulator in fixed relation to the shaft; whereby each turbulator is removably attached to the common shaft independently of the other turbulators.
 2. The boiler apparatus according to claim 1 wherein the turbulator is arranged depending downwardly from a location radially of the axis of the shaft such that the ear extends outwardly from the shaft in a generally radial direction relative thereto, and the removable pin comprises an elongate pin portion extending generally diametrically through the shaft through said cooperating apertures and a clip portion following an arcuate curving path about a circumferential periphery of the shaft from one end of the pin portion where the clip portion is pivotally connected to the pin portion to an opposite end of the pin portion where a terminus of the clip portion is matingly securable to the pin portion externally of the shaft.
 3. The boiler apparatus according to claim 2 wherein the clip portion of the pin follows the arcuate curving path about a portion of the circumferential periphery of the shaft that is opposite the ear from which the turbulator depends.
 4. The boiler apparatus according to claim 1 wherein the turbulators are at spaced positions along the shaft each longitudinally of the next.
 5. The boiler apparatus according to claim 1 wherein the turbulators are disposed in an alternating arrangement relative to the shaft such that the turbulators are staggered relative to one another about the axis of the shaft.
 6. The boiler apparatus according to claim 1 wherein the pin portion where it passes through the bracket and shaft has a smooth cylindrical surface. 